Methods for coating and patching with asphalt compositions

ABSTRACT

An aggregate containing asphalt composition comprised of aggregate and a non-emulsified asphalt binding composition comprising (1) a medium curing liquid asphalt, and (2) from about 0.1 to 13.5% by weight tall oil based on the weight of the medium curing liquid asphalt is applied as a coating.

BACKGROUND OF THE INVENTION Cross Reference to Related Application

This application is a continuation-in-part application of copendingapplication Ser. No. 06/205,151, now U.S. Pat. No. 4,373,960, filed onNov. 10th, 1980, which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to asphalt patching, paving or repaircompositions, sealing or coating compositions, and methods for coating,repairing, paving or patching structures such as roadways, such asasphaltic surfaces. The compositions and methods are applicableparticularly to repairing or patching potholes, and the like, usuallycaused by weather and temperature variations and to repairing utilitycuts in roadways. More particularly, the present invention relates toasphalt compositions that can be packaged and used for small roadrepairs or can be stored in bulk stock piles, and used for the desiredrepairs without on-site heating or other thermal control of the asphaltcompositions.

DESCRIPTION OF THE PRIOR ART

Numerous disadvantages are associated with prior art methods and asphaltcompositions generally used for the patching of roads and othersurfaces. Hot asphalt compositions that are generally used in patchingroads become stable upon cooling. In order to prevent the prematurecooling of such compositions prior to use, special equipment is not onlyrequired to produce these compositions, but also to transport thesecompositions, in a heated state, to the site of the repair. It isnecessary to maintain the compositions at the desired elevatedtemperature until the completion of the job, resulting in considerablelabor and other expenses for the exercise of thermal control. Furthertransportation of these heated mixtures is limited by traffic conditionsand weather conditions, such as rain and snow.

Once at the working site, the hot asphalt compositions must bemaintained at the proper temperature until used. When used in a patchingoperation, a crew of, for example, four to seven skilled personnel arerequired for the raking, hot ironing, tamping and subsequent hot-rollingof the composition so that the composition is softened andsatisfactorily secured to the existing roadway being repaired. Anotherdrawback with such hot asphalt compositions is that these compositionscannot be used in patching operations while raining or snowing becausethe rain or snow tends to abnormally cool the hot compositions andprevents the hot compositions from satisfactorily adhering to theroadway. Further, such hot mixes are generally transported in fulltruckloads to the site of a repair in order to conserve heat. Quiteoften, much of the material becomes too cold and therefore too hard touse and is therefore wasted. Additional costs are thereby incurred forthe asphalt not used as well as the disposal of the asphalt.

A still further serious drawback in the use of the prior art patchingcompositions relates to the expansion and contraction of the patches dueto changes in weather and temperature conditions which facilitates theintroduction of water beneath the patch and surrounding roadway. Ifwater seeps through the patched area, it will spread to the base andsub-base of the roadway, causing continuing disintegration of theroadway as a result of the perma-frost effect, leading to more extensiverepairs and an attendant increase in costs for repairing the road.

Cold asphalt mixes containing cut-back asphalts, slow-curing asphaltsand emulsified asphalts which can be stockpiled are in common use today.These mixtures depend upon the evaporation of solvents or water to causesufficient hardening to prevent displacement under traffic. Quite often,however, these cold patches are displaced by traffic before completehardening is achieved, resulting in the need for additional applicationof a cold patching composition at the repair site. In addition, coldasphalt mixes, such as those in the form of emulsions, are generally notstable over long periods of time and generally must be used shortlyafter the preparation thereof to prevent the separation of theingredients of the compositions. An example of an asphalt composition inthe form of an emulsion containing water is disclosed in U.S. Pat. No.3,867,162 to Elste, Jr.

A need therefore exists for an aggregate containing asphalt compositionthat can be used as a patching composition that is capable of overcomingthe various disadvantages associated with various prior artcompositions.

SUMMARY OF THE INVENTION

It is therefore a primary object of the present invention to provide anaggregate containing asphalt composition comprised of a coated aggregateuseful as a patching composition for roads that facilitate instant,permanent and economical road repairs in a simple and efficient manner.

Consistent with this primary object, it is also an important object ofthe present invention to provide an aggregate containing asphaltcomposition useful as a patching composition, that can be used yearround, under extreme temperature conditions, from below 0° to above 100°F. without the need of heating or maintaining the composition at anelevated temperature just prior to use. Such compositions remainsufficiently workable, even during cold temperature conditions, to beremoved from a stock pile and worked into the surface area beingrepaired.

Another object of the present invention is to provide an aggregatecontaining asphalt composition, useful as a patching composition, thatcan be packaged in bags or other low-cost containers, in small or largequantities, facilitating both short-term and long-term storage of thecomposition and ease of transportability to the repair site.

A further object of the present invention is to provide a compositionthat exhibits a shelf life of greater than one year, even when exposedto air, sun, light and rain.

Still another object of the present invention is to provide an aggregatecontaining asphalt composition, useful as a road repair or patchingcomposition, that flows freely, is self-feathering and self-adhering andcapable of adhering to bituminous surfaces, especially asphalt surfaces,bituminous concrete surfaces or other surfaces such as concrete, steel,earth or wooden surfaces, both under wet and dry weather conditions.

A still further object of the present invention is to provide anaggregate containing asphalt composition, useful as a patchingcomposition, that does not require skilled labor or expensive machinery,including rollers, for the filling of a discontinuity in a roadway.

Other objects of the present invention are to provide an asphalt bindercomposition which can be mixed with aggregate to form the aggregatecontaining asphalt composition, useful as a patching or pavingcomposition, a coating or sealing composition which can be applied tothe roadway before application of the patching composition, and methodsfor preparing and applying the various compositions.

Additional objects and advantages of the present invention will be setforth in the description which follows and in part will be obvious fromthe description or can be learned by practice of the invention. Theobjects and advantages are achieved by means of the compositions,processes, instrumentalities and combinations particularly pointed outin the appended claims.

To achieve the foregoing objects and in accordance with its purpose thepresent invention relates to an asphalt binder composition useful withaggregate particles such as mineral aggregate to form an aggregatecontaining asphalt composition which can be used as a patchingcomposition. The asphalt binder composition comprises: (1) a mediumcuring liquid asphalt, and (2) from about 0.1 to 13.5% by weight talloil based of the weight of the medium curing liquid asphalt.

In another embodiment of the present invention there is provided anaggregate containing asphalt composition which comprises the asphaltbinder composition, as defined above, and aggregate, preferably mineralaggregate. Preferably, the aggregate containing asphalt compositioncomprises from about 3 to 8%, preferably 5.25 to 7% by weight of asphaltbinder composition, defined above, and from about 97 to 92%, preferably94.75 to 93% by weight of aggregate, preferably mineral aggregate, basedon the weight of asphalt binder composition plus aggregate.

The asphalt binder composition is generally prepared by initially mixingtogether the various ingredients of the asphalt binder composition at atemperature sufficient to cause the composition to flow. Generally,temperatures of between about 120° and 200° F. are used. Preferably, thetemperature should not exceed 170° F. when working with a medium cureliquid asphalt of designation MC-800. Thereafter, and while still hot,the liquid asphalt binder composition is mixed with the mineralaggregate to coat the aggregate particles and form the aggregatecontaining asphalt composition useful as a patching composition.

The present invention also relates to a method for patching or repairinga structure such as a roadway having a local discontinuity therein,comprising: (a) spreading out over the discontinuity and about theperimeter of the discontinuity, a coating or sealing compositioncontaining a rapid curing liquid asphalt and tall oil in an amount fromabout 0.1 to 13.5% by weight tall oil, preferably 1% by weight tall oil,based of the weight of rapid curing liquid asphalt to form a firstcoating, and (b) thereafter applying on the top of the first coating theabove described aggregate containing asphalt composition useful as apatching composition.

The invention further provides a patch or coating comprising a firstlayer of the above described rapid cure asphalt sealing composition anda second layer covering the first layer, the second layer comprising theabove described aggregate containing medium cure asphalt useful as apatching composition.

The various binder compositions, aggregate containing asphaltcompositions useful as patching compositions, and rapid cure asphaltsealing compositions of the present invention as described above containessentially no water and are not in the form of an emulsion such as awater-containing emulsion.

It is to be understood that both the foregoing general description andthe following detailed description of this invention are exemplary, butare not restrictive of the invention.

DETAILED DESCRIPTION OF THE INVENTION

The asphalt binder compositions used in the practice of the presentinvention generally contain a medium curing liquid asphalt as their maincomponent. The asphalt binder compositions generally contain from about88% to about 99.9% by weight, and preferably 95% to 99% by weight ofmedium curing liquid asphalt, based on the weight of medium curingliquid asphalt plus tall oil. Particularly good results have beenachieved when the binder composition contains about 99% by weight ofmedium curing liquid asphalt.

The medium cure asphalts used in the present invention for bindingpurposes are usually designated with the letters MC, e.g., MC-250,MC-800 and MC-3000. These asphalts are generally blended, at therefinery, with petroleum fractions such as naptha, kerosene or furnaceoils, to yield the desired low viscosity "cutback grades" such as thosedefined hereinbefore. Exemplary properties of these "cutback grade"asphalts are set forth in Table I, below taken from The AsphaltHandbook, The Asphalt Institute, July 1962 Edition.

                                      TABLE 1                                     __________________________________________________________________________              AASHO                                                                              ASTM                                                                     Test Test                                                           Characteristics                                                                         Method                                                                             Method                                                                             MC-250                                                                             MC-800                                                                             MC-3000                                         __________________________________________________________________________    Flash Point                                                                             T79  D 1310                                                                             150+ 150+ 150+                                            (Open Tag.) °F.                                                        Kinematic      D 445                                                                              250-500                                                                            800-1600                                                                           3000-6000                                       Viscosity at                                                                  140° F., c.s.                                                          Distillation-                                                                 Distillate (percent                                                           of total distillate                                                           to 680° F.):                                                           To 437° F.                                                                       T78  D 402                                                                              0.10 --   --                                              To 500° F.                                                                       T78  D 402                                                                              15-55                                                                              35-  15-                                             To 600° F.                                                                       T78  D 402                                                                              60-87                                                                              45-80                                                                              15-75                                           Residue from                                                                            T78  D 402                                                                              67+  75+  80+                                             distillation to                                                               680° F., volume                                                        percent by                                                                    difference                                                                    Tests on Residue                                                                        T49  D 5  120-250                                                                            120-250                                                                            120-250                                         from Distillation                                                             Penetration, 77° F.,                                                   100 g, 5 sec.                                                                 Ductility, 77° F.,                                                               T 51 D 113                                                                              100+ 100+ 100+                                            cms                                                                           Solubility in                                                                           T 44 D 4  99.5+                                                                              99.5+                                                                              99.5+                                           Carbon                                                                        Tetrachloride, %                                                              Water, %  T 55 D 95 0.2- 0.2- 0.2-                                            __________________________________________________________________________

The particular medium cure asphalt used is largely dependent uponambient temperatures. For example, with warm weather it would be desiredto use a medium cure asphalt exhibiting a high viscosity, such as MC-800or MC-3000 whereas in cold weather, it would be desired to use a mediumcure asphalt exhibiting a low viscosity, such as MC-250.

The asphalt binder composition further comprises tall oil. The tall oilpromotes the adhesion of the binder composition, when admixed with anaggregate material, to the aggregate particles and to the existingroadway being patched or repaired. The tall oil aids the asphalt to setup and aids the binder composition in releasing from vehicle tires.Generally, between about 0.1 and 13.5%, and preferably between about 0.5and 5% by weight of tall oil is present in the asphalt bindercompositions of the present invention, based on the weight of the mediumcure liquid asphalt. Most preferably, the tall oil is present in anamount of between 0.75 and 3% by weight. Particularly good results areobtained when tall oil is present at 1% by weight of the medium cureliquid asphalt.

The primary source of tall oil used in the practice of the presentinvention is from pine trees. Besides cellulose, tall oil contains fattyacids, esters, rosin acids, sterols, terpenes, carbohydrates and lignin.These are separated when wood is converted to paper pulp by the sulfideor Kraft process. The acids are then neutralized in an alkalinedigestion liquor. The mixture of rosin and fatty acid soap are recoveredby subsequent acidification which releases free rosin and fatty acids,the major constituents of tall oil.

Particularly preferred tall oils useful in the practice of thisinvention include tall oils that contain from about 12 to about 28% byweight rosin acids, from about 68 to about 86% by weight fatty acids,and from about 2 to about 30% by weight of unsaponifiables. An exampleof a tall oil useful in the practice of this invention contains 70.4%fatty acids, 28.0% rosin acids and 1.6% unsaponifiables. This tall oilexhibits a minimum acid number of 180 and a saponification number of193. Best results are obtained with a tall oil containing 86% fattyacids, 12% rosin acids and 2.0% unsaponifiables. Other properties ofthis tall oil are set forth in Table 2, below.

                  TABLE 2                                                         ______________________________________                                        SPECIFICATIONS                                                                Acid No.        190 Minimum ASTM D 803                                        Rosin Acid      15% Maximum ASTM D 1240                                       Unsaponifiable  3.0 Maximum ASTM D 803                                        Color (Gardner) 7 Maximum   ASTM 1544-68                                      TYPICAL PROPERTIES                                                            Saponification No.                                                                            194.5       ASTM D 803                                        Iodine Value    134         ASTM D 1959                                       Viscosity       A-2         ASTM D 803                                        (Gardner-Holdt, 250° C.)                                               Specific Gravity                                                                              905                                                           25° C./25° C.                                                   Flash Point (C.O.C.)                                                                          405° F.                                                                            ASTM D 92                                         Fire Point (C.O.C.)                                                                           435° F.                                                                            ASTM D 92                                         Titer           3° C.                                                                              ASTM D 1982                                       TYPICAL COMPOSITION                                                           Fatty Acids, %  86          ASTM D 803                                        Rosin Acids, %  12          ASTM D 1240                                       Unsapifiables, %                                                                              2.0         ASTM D 803                                        ______________________________________                                    

Rosin acids in tall oil present generally include pimaric acid,palustric acid, 1-pimaric acid, levopimaric acid, isopimaric acid,abiatic acid, dehydroabetic acid and neoabietic acids.

Other tall oil products can also be used, such as, for example, crudetall oil, tall oil head, distilled tall oil, tall oil pitch and thelike.

The tall oil and medium cure liquid asphalt can be the only componentsin the asphalt binder composition of the present invention.

In addition to the tall oil and medium cure liquid asphalt components,the asphalt binder composition can contain, but need not contain, aneffective amount of an organopolysiloxane fluid that is present in anamount sufficient to promote the release of tires of motor vehiclescoming into contact with the asphalt binder composition of the presentinvention. Organopolysiloxanes that may be used in the practice of thisinvention may be represented by the general formula: ##STR1## wherein Rand R', which may be the same or different, each represent monovalenthydrocarbon radicals or halogenated monovalent hydrocarbon radicalshaving from 1 to 18 carbon atoms and n is a number greater than 20.

Radicals represented by R above are alkyl radicals, e.g., methyl, ethyl,propyl, butyl, octyl, dodecyl and octodecyl; arylradicals, e.g., vinyl,allyl radicals; cycloalkyl radicals, e.g., cyclobutyl, cyclopentyl andcyclohexyl; alkaryl radicals, e.g., totyl, xylyl, ethylphenyl; aralkylradicals, e.g., benzyl, -phenylethyl, -phenylethyl and -phenylbutyl; andthe halo substituted radicals enumerated above.

The organopolysiloxane may be any linear or branched chained compoundhaving an average from 1.75 to 2.25 organic radicals per silicon atom.Generally, it is preferred that the organopolysiloxane be free ofterminal hydroxyl groups. However, a small number of terminal-hydroxylgroups will not materially affect the release properties of thecomposition. The organopolysiloxanes may have a minor amount ofmolecules having only one hydroxyl group or there may be a small numberof molecules carrying an excess of two hydroxyl groups. However, asmentioned previously, it is preferred that the organopolysiloxane besubstantially free of hydroxyl groups. In general, the polysiloxanefluids have a viscosity of between about 10,000 and 600,000 cs., andmore preferably between about 50,000 and 400,000 cs., at 25° C.

The preferred organosiloxane useful in the practice of the invention isa dialkylsiloxane, with dimethyl silicone being particularly preferred.

Generally, the asphalt binder composition can contain between about0.0001 and 0.05 volume %, and preferably between about 0.000567 and0.0385 volume %, of organopolysiloxane, based on the volume of mediumcuring liquid asphalt plus tall oil. Most preferred results forcompositions containing organosiloxane are obtained when the asphaltbinder composition contains about 0.0068% by volume oforganopolysiloxane such as dimethyl silicone.

The aggregate containing asphalt compositions, useful as patchingcompositions, of the present invention generally comprise a mineralaggregate in combination with the previously defined asphalt bindercomposition. The asphalt binder composition is present in an amountsufficient to coat the mineral aggregates, and this amount generally isbetween 3 and 8% by weight and preferably between about 5.25% and 7% byweight, based on the total weight of the aggregate containing patchingcomposition. The mineral aggregate particles of the present inventioninclude calcium based aggregates, for example, limestone, siliceousbased aggregates and mixtures thereof.

A preferred aggregate is bird's eye or rice stone aggregate which is acoarse mix limestone aggregate which exhibits the following sieveanalysis

    ______________________________________                                                    Cumulative % By Weight                                            Sieve Size  Passing Corresponding Sieve                                       ______________________________________                                        1/2"        100%                                                              3/8"         90-100%                                                          #4          20-60%                                                            #8           0-25%                                                            #16          0-10%                                                            #50          0-5%                                                             #200         0-3%                                                             ______________________________________                                    

When using a coarse mix aggregate, it is preferred to use between about5.25 and 6.5%, most preferably 5.25 and 5.5% of asphalt bindercomposition based on the total weight of the patching composition.

A particularly preferred aggregate is a fine limestone aggregate whichexhibits the following sieve analysis:

    ______________________________________                                                     Cumulative %                                                                  By Weight Passing                                                Sieve Size   Corresponding Sieve                                              ______________________________________                                        3/8"         100%                                                             #4           94.5%                                                            #8           79.1%                                                            #16          64.6%                                                            #30          52.6%                                                            #50          34.8%                                                            #100         21.0%                                                            #200         10.9%                                                            ______________________________________                                    

The limestone aggregates generally exhibit the following chemicalanalysis:

Calcium Oxide is calculated to Calcium Carbonate: 62.78%

Magnesium Oxide is calculated to Magnesium carbonate: 14.67%

Silica: 16.44%

Iron: 1.01%

Aluminum: 1.26%

Calcium Oxide: 35.27%

Magnesium Oxide: 7.02%

Loss on ignition: 33.03%

Sulphur: 0.09%

When using a fine mix aggregate, such as a fine mix limestone, it ispreferred to use between about 6.5% and 7% of asphalt binder compositionbased on the total weight of the patching composition, with 7% beingmost preferred.

A particularly preferred mineral aggregate mixture comprises 20% byweight washed concrete sand and 80% by weight of a limestone aggregatewherein all of the limestone aggregate material passes through a #10screen. The typical sieve breakdown of the washed concrete sand is:

    ______________________________________                                                    Cumulative % By Weight                                            Sieve Size  Passing Corresponding Sieve                                       ______________________________________                                        3/8"        100%                                                              #4          96.2%                                                             #8          82.1%                                                             #16         68.6%                                                             #30         50.9%                                                             #50         20.3%                                                             #100         4.0%                                                             ______________________________________                                    

This preferred mineral aggregate mixture is generally used with about6.5% by weight of the asphalt binder composition the weight being basedupon the total weight of the aggregate containing composition which isuseful as a patching composition.

Aggregates other than limestone can be used in the practice of thepresent invention. For example, gravel or crushed rock, volcanic ash,sand, pumice, burned clay, coal particles, slag, and the like can beused. Mixtures of different aggregates can also be used.

The aggregate containing asphalt composition of the present inventioncan be used to provide a shell or lining for containing liquids, and canbe pumped to the area which is to be lined, such as by pumping to anunderground location to line the banks of ponds. In the presentinvention, lead, for example, powdered lead, can be used as theaggregate, especially when the aggregate containing asphalt compositionis to be used to provide a shell or lining for containing liquidpollutants, such as those which contain radioactive waste. The leadaggregate can be present in an amount of 92 to 97% by weight based onthe total weight of the aggregate containing asphalt composition, withremainder being the asphalt binder composition. Greater or lesseramounts of lead can be provided depending on the amount of radioactiveprotection that may be desired.

The present invention also provides aggregate containing asphaltcompositions which contain non-mineral aggregates. These non-mineralaggregates can be used as the only aggregates in the aggregatecontaining asphalt composition, or can be used as a mixture with themineral aggregates. Suitable non-mineral aggregates, for example, arethermoplastic synthetic polymers such as polypropylene which can beadded in the form of polypropylene spheres. An aggregate containingasphalt composition containing polypropylene spheres can be used as alight weight and desirable protective lining or coating for, forexample, the hull of a ship.

The asphalt binder compositions of the present invention are generallyprepared by adding the tall oil, and when present the organopolysiloxanesuch as dimethyl silicone, to the medium cure asphalt and mixing theseingredients together at a temperature of between 120°and 200° F.,preferably in a heated tank. Preferably, the temperature should notexceed 170° F. when working with a medium cure liquid asphalt ofdesignation MC-800. With a higher designation, such as MC-3000, highertemperatures can be used. Similarly, with a lower designation, lowertemperatures are preferably used. The asphalt binder composition isconstantly circulated at the elevated temperature for a period of timeto ensure good mixing, and generally between 2 and 3 hours.

The asphalt binder compositions of the present invention can alsocontain various additives, such as non-toxic dyes, for example, agasoline red dye which can be added in an amount of a few ounces (e.g.,1 to 8 ounces) per 5000 gallons of binder composition. Moreover, theasphalt binder composition can contain additives which promote thewetting of the asphalt binder composition to the aggregate. Theseadditives can comprise, for example, fatty acids, such as long chainfatty acids, for example, oleic, stearic or cocoa fatty acids. Thewetting additives preferably are used in amounts of from about 0.5 to1.5%, based on the weight of the asphalt binder composition. A typicaladditive that has been used is known by name Kling Beta KY modifiedadditive, sold by Lancaster Chemical, New Jersey. The various additivesare added to the asphalt and mixed therein together with the tall oiland organopolysiloxane, such as dimethyl silicone. The order of additiongenerally is immaterial.

The liquid asphalt binder composition is then applied to the mineraland/or non-mineral aggregate that is free of foreign or deleterioussubstances, such as surface moisture, preferably in a batch plant mixer,for a period of time sufficient to thoroughly coat the mineral and/ornon-mineral aggregate particles. In the event that the mineral and/ornon-mineral aggregate does contain surface moisture, the mineral and/ornon-mineral aggregate is initially dried by heating the mineral and/ornon-mineral aggregate at an elevated temperature up to 150° F. Mixingshould be continuous until all aggregates are thoroughly coated with thebinder composition.

A particularly preferred repair or patching composition, based on 1 tonof finished paving composition contains 1895 pounds of 1/4 inch ricestone or 1/4 inch birdseye limestone; 103.95 pounds of MC 250 or MC 800asphalt, 1.5 pounds of distilled tall oil having the characteristics ofTable 2 above, and 1 cc of dimethyl silicone. The dimethyl silicone canvary from about 5 drops to 10 cc for one ton of finished patchingcomposition. The patching composition can also contain from 1 cc to 2ounces of non-toxic dye and from 0.5 to 1.5 percent of a suitablewetting additive.

The resulting patching compositions may be either used immediately afterpreparation or stored for subsequent use at some future date, in view ofits shelf life being greater than one year.

When using the patching compositions of the present invention for therepair of roads, having a local discontinuity therein, the discontinuitybeing in the form of utility cuts or damaged surface areas includingpotholes, cracks, surface wear and the like, a sealer compositionpreferably is initially applied over the discontinuity in an amountsufficient to cover the discontinuity and surrounding roadway. Bysurrounding roadway, it is intended to include the perimeter of thediscontinuity and extending at least about one inch away from thediscontinuity.

The sealer composition prevents the penetration of water through thesurface to the base and sub-base of the roadway which is being repaired.

In accordance with a preferred embodiment of the present invention, thesealer or coating composition comprises generally between 88 and 99.9%and preferably between 95 and 99% by weight of a rapid curing liquidasphalt based on the weight of rapid cure liquid asphalt plus tall oil,and between 0.1 and 13.5% by weight, and preferably between 0.5 and 5%by weight of tall oil, based on the weight of rapid curing liquidasphalt. Most preferably, the tall oil is present in an amount ofbetween 0.75 and 3% by weight, with particularly good results beingachieved when the tall oil is present at about 1% by weight.

Preferably, the sealer composition also contains an organopolysiloxane.The organopolysiloxane used in the sealer composition preferably is thesame as used in the binder composition, and most preferably is dimethylsilicone. Preferably, the organopolysiloxane is used in an amount ofbetween about 0.0001 to 0.05 by volume, based on the volume of rapidcuring liquid plus tall oil and preferably in an amount of 0.0001 to0.005% by volume. Particularly good results have been achieved using theorganopolysiloxane in an amount of 0.00027% by volume which amounts toabout 2 drops per 40 pounds (5 gallons) of the sealer composition. Thesealing composition is liquid in hot and cold weather, sets up quicklywhen applied to a roadway, and cures in a few hours when applied to aroadway. The sealing composition can be prepared generally in the samemanner as the asphalt binder composition by mixing the variousingredients together at a temperature sufficient to maintain liquidityand generally between about 140° to 220° F. for about 2 hours. Thesealing composition can then be packaged.

The rapid curing asphalts used in the present invention are conventionalasphalts that are generally designated in the art with the letters RC,e.g., RC-250, RC-800 and RC-3000. These asphalts are generally blended,at the refinery, in the same manner as the medium curing asphalts anddiffer from the medium curing liquid asphalts in the required timerequired to harden or otherwise set.

The properties of two rapid curing asphalts are set forth in Table 3,below:

                  TABLE 3                                                         ______________________________________                                                           Sample 1                                                                              Sample 2                                                              RC-250  RC-800                                             ______________________________________                                        Gravity A.P.I.       15.4      13.2                                           Specific Gravity at 60° F.                                                                  0.9632    0.9779                                         Flash, ° F.   98        100                                            Furol Viscosity at 140° F.                                                                  170       171                                            Kinematic Viscosity @ 140° F.                                                               340       1370                                           Wt./Gallon           8.021     8.144                                          DISTILLATION: % of Total Distillate to 680° F.                         0-320° F.     7.0                                                      0-374° F.     55.8      35.7                                           0-437° F.     79.1      64.3                                           0-500° F.     86.0      82.1                                           0-600° F.     95.3      96.4                                           Residue, Vol. % by Difference                                                                      78.5      86.0                                           TESTS OF RESIDUE FROM DISTILLATION:                                           Penetration at 77° F./100 Grams/5 Sec.                                                      117       116                                            Ductility at 77° F./5 cm. per min., cm                                                      100+      100+                                           Softening Point °F.                                                    Solubility in Trichloroethylene                                                                    99.9      99.9                                           ______________________________________                                    

The sealer composition can be applied by conventional coating techniquesincluding, for example, brushing, rolling, and the like.

Once the sealer composition has been spread over the completediscontinuity and that portion of the roadway immediately adjacent thediscontinuity, the patching composition of the present invention is thenapplied in an amount sufficient to fill the discontinuity to a level atleast equal to the surrounding roadway and preferably at least one inchabove the surrounding roadway. The patching composition is generallyapplied in the form of a rectangle or square for aesthetic purposes.Once applied, the patching composition is then feathered automaticallyby the traffic passing thereover.

As noted hereinbefore, the sealer composition and patching compositioncan be satisfactorily used for the repair of utility cuts. Such utilitycuts are generally made for the repair of gas, electric and water linerepairs. After completing the utility repair, the earth is thencompacted, crushed rock is placed thereover and compacted, followed bythe application of the sealer composition, and, finally, the patchingcomposition of the present invention. The use of the sealer compositionand patching composition provides a permanently sealed, aestheticallypleasing, economical and time saving repair of a roadway.

In the conventional repair of utility cuts, a temporary repair isgenerally made in which the roadway is first dug out, the earth is thenput back, and a temporary pavement is then applied. A number of dayslater, the temporary repair is replaced with a permanent repair in whicha concrete base is applied, and then a hot asphalt pavement is appliedby a hot crew. The permanent repair is applied to a large area which issignificantly larger than the area of the utility cut itself. Thus,conventional permanent repairs of utility cuts usually extend forone-half the width or the full width of the roadway being repaired, andextend a significant distance (e.g. three or four feet) along the lengthof the roadway. In contrast, when repairing utility cuts in accordancewith the present invention, there is no need to apply a temporaryrepair, and the area which is repaired need be only the area of theutility cut itself plus whatever small area is needed to achieve anaesthetic effect by, for example, squaring the repair. The practice ofthe present invention thus allows significant savings to be achieved intime and costs for repair of utility cuts.

In the conventional repair of potholes in an aesthetic manner, the pothole is squared or otherwise shaped by cutting out good pavementmaterial and then applying hot asphalt in the area of the original pothole and in the enlarged area where the good material was cut. Moreover,the cutting of good material results in a further joint area where watercan seep and further destroy the roadway because of the perma-frosteffect. In contrast, in the present invention, there is no need to cutout good material, but simply to apply the sealer composition in anaesthetic manner to the pot hole and surrounding roadway, as discussedabove, and then apply the patching composition.

It is noted that in the preferred embodiments of the present invention,both the sealer composition and patching composition are used for therepair of a discontinuity. However, it is also possible to make such arepair with the use of the patching composition alone which is appliedto the discontinuity and the roadway immediately adjacent thediscontinuity.

Utility companies often drill holes in the ground or roadway in attemptsto locate leaks, such as gas leaks, and the patching composition can befiled into these holes to repair the holes and cover them up.

It is understood that the compositions of the present invention, as wellas the embodiments relating to the process of repairing roadways, isapplicable to roadways such as asphalt, concrete or dirt roadways.

The use of patching compositions in accordance with this invention canbe used to fill a discontinuity by the simple means of a shovel andwithout the necessity of expensive equipment. The road repair method andcompositions of the present invention facilitate instant, permanent,economical paving repairs that can be performed year round, winter orsummer, on both wet or dry surfaces.

The patching composition before it is applied to the roadway flowsfreely, is flexible, has a wet oatmeal like consistency, and can bestored and used at temperatures of from about below 0° F. (e.g. -25° F.)to above 100° F. (e.g. 110° F.), and is easily workable at theseconditions. As noted hereinbefore, when applied to roadways, thepatching composition is both self-feathering and self-adhering. In wetor dry weather it adheres to bituminous concrete, concrete, steel, dirtor wooden surfaces and sets up in as hard and permanent manner. Repairsin accordance with the present invention withstand immediate traffic. Infact, the more traffic passing over the repair, the stronger the roadrepair composition becomes. This pressure, together with oxidation,sunlight, rain, increase of viscosity due to the evaporation ofsolvents, and crystallization of the patching composition, facilitatesthe rapid set up of the patching composition once used.

To use the patching composition, all that needs to be done is to shovelthe material into holes and level it, about one inch above the existingpaving. It does not require skilled labor such as is used in the hotasphalt process. The patching composition provides for instant,permanent, economical paving repairs, year round, winter or summer andworks on wet or dry payment. No raking, bonding agents, or feathering isrequired, just leveling. Further, there is no need for rollers ortampers. Traffic compacts and feathers the material making it capable ofinstant paving repairs. There is no need for waiting time, curing time,or compacting time, since the road repair composition withstandsimmediate traffic. The greater amount of traffic, the faster it sets upand the stronger the road repair composition becomes.

The patching composition has an ability to maintain its freshness, easeof workability, exceptional ability to adhere to the old paving evenwhen the chuck hole is filled with water and as ease of handling evenwithout skilled labor. It has an ability to tightly stick to the oldpavement and at the same time, rubber tires and synthetic tires do notstick to the patching composition, but are released therefrom withoutpulling or breaking up the patching composition. Under pressure andtraffic, the more traffic the better, the road repair composition beginsits setting up period. The material feathers out automatically so thatthe material seals itself against the edges of the pothole. After aperiod of time, for example, 24 to 48 hours, the patching compositionbecomes as strong and hard as the surrounding surfaces. Oxidation overfurther periods of time completes the hardening process.

It is further noted that the aggregate containing asphalt compositions,such as those useful as patching compositions, of the present inventioncan be packaged and used for small repairs or they can be stored in bulkstock piles, in maintenace yards, for periods greater than one yearwithout the separation of ingredients which is generally experiencedwith prior art emulsion-type patching compositions useless for theirintended purpose. The aggregate containing asphalt composition, such asthat used as a patching composition, has a shelf life of at least oneyear when in paper bags having a polyethylene middle lining, and atleast a year when stock piled in the open, even though it is exposed toair, sunshine and rain.

For special purposes, one or more special aggregates can be added to theaggregate containing asphalt composition, such as those useful as apatching composition, such as light absorbing chemical which will absorblight during the day and radiate light at night; fluorescent orphosphorescent materials; glass, reflective materials, or colorindicators similarly, magnetic or radioactive signatures or markers caneasily be incorporated into the aggregate containing aspahlt compositionsuch as the patching composition, during or after it is manufactured.These special aggregates can comprise the only aggregates in theaggregate containing asphalt compositions or can be mixed with mineralaggregates. The aggregate containing asphalt compositions containing oneor more of these special aggregates can be applied as a coating layer ona surface to be coated to obtain the special effect of the specialaggregate.

It will be understood that the above description of the presentinvention is susceptible to various modifications, changes andadaptations, and the same are intended to be comprehended within themeaning and range of equivalents of the appended claims.

What is claimed is:
 1. In a method for patching a structure having alocal discontinuity therein comprising:(a) spreading out over saiddiscontinuity and the surface area defining the perimeter of saiddiscontinuity, a coating composition, comprising a rapid curing liquidasphalt and from about 0.1 to 13.5% tall oil, based on the weight of therapid curing liquid asphalt to form a first coating; (b) applying on thetop of said coating a patching composition comprising: (1) mineralaggregate in combination with (2) a non-emulsified asphalt bindercomposition which contains essentially no water and comprising a mediumcuring liquid asphalt, and tall oil, said asphalt binder compositionbeing present in an amount sufficient to fill said discontinuity to alevel at least equal to the structure defining the perimeter of saiddiscontinuity.
 2. The method of claim 1 comprising filling saiddiscontinuity with said patching composition to a height of about oneinch above the surrounding structure.
 3. The method of claim 1, whereinsaid asphalt binder composition comprises from 0.1 to 13.5% by weighttall oil based on the weight of the medium curing liquid asphalt.
 4. Themethod of claim 3, wherein said asphalt binder composition contains from0.5 to 5% by weight tall oil, based on the weight of the medium cureasphalt.
 5. The method of claim 1, wherein said aggregate is limestone.6. The method of claim 3, wherein said tall oil consists essentially of70.4% by weight fatty acids, 28.0% by weight rosin acids, and 1.6% byweight unsaponifiables.
 7. The method of claim 1, wherein said asphaltbinder composition contains an organopolysiloxane.
 8. The method ofclaim 7, wherein the organopolysiloxane is present in an amount of0.0001 to 0.05% by volume of organopolysiloxane based on the volume ofmedium curing liquid asphalt plus tall oil in the asphalt bindercomposition.
 9. The method of claim 7, wherein the organopolysiloxane isdimethylsilicone.
 10. The method of claim 1, further comprising the stepof feathering said patching composition to form an aesthetic patch. 11.The method of claim 1, wherein said tall oil is present in the asphaltbinder composition in an amount of 0.75 and 3% by weight, based on theweight of the medium cure asphalt.
 12. The method of claim 1, whereinsaid tall oil is present in the asphalt binder composition in an amountof about 1% by weight, based on the weight of the medium curing liquidasphalt.
 13. In a method for coating a surface comprising applying tothe surface an aggregate containing asphalt composition comprising: (1)aggregate in combination with (2) a non-emulsified asphalt bindercomposition which contains essentially no water and comprising a mediumcuring liquid asphalt, and tall oil.
 14. The method of claim 13, whereinsaid asphalt binder composition comprises from 0.1 to 13.5% by weighttall oil based on the weight of the medium curing liquid asphalt. 15.The method of claim 13, wherein said asphalt binder composition containsfrom 0.5 to 5% by weight tall oil, based on the weight of the mediumcuring liquid asphalt.
 16. The method of claim 13, wherein saidaggregate is a mineral aggregate.
 17. The method of claim 14, whereinsaid tall oil consits essentially of 70.4% by weight fatty acids, 28.0%by weight rosin acids, and 1.6% by weight unsaponifiables.
 18. Themethod of claim 13, wherein said asphalt binder composition contains anorganopolysiloxane.
 19. The method of claim 18, wherein theorganopolysiloxane is present in an amount of 0.0001 to 0.05% by volumeof organopolysiloxane based on the volume of medium curing liquidasphalt plus tall oil.
 20. The method of claim 18, wherein saidorganopolysiloxane is dimethylsilicone.
 21. The method of claim 18,wherein said aggregate is a mineral aggregate.
 22. The method of claim13, wherein said tall oil is present in an amount of 0.75 and 3% byweight, based on the weight of the medium cure asphalt.
 23. The methodof claim 13, wherein said tall oil is present in an amount of about 1%by weight, based on the weight of the medium curing liquid asphalt. 24.The method of claim 13, wherein the aggregate containing asphaltcomposition is applied to a discontinuity in a structure.